Adjustable modular partition

ABSTRACT

An adjustable modular partition including at least three layers of interconnected fire resistant and sound deadening material with adjusting means located thereon to adjust the vertical height of the partition module to accommodate various vertical dimensional differences in a room. Each module is provided with means for interconnection with an adjacent module with similar adjusting structure to accommodate vertical variations in dimension. The structure for interconnecting adjacent modules and the respective adjusting structure also has sound deadening and fire resistant qualities to maintain the integrity of the partition system. Minimal connecting apparatus is required to install the partitions in fixed position within a room.

United States Patent Guarino et al. 1 Dec. 2, 1975 1 1 ADJUSTABLE MODULAR PARTITION 3,553,921 1/1971 Breistein 52/615 x 3 2 [75] Inventors: Michael C. Guarino, Rumson; Frank 12/1973 schneuer 52/6 7 X Cacossa, Livingston, both of NJ. Primary ExaminerPrice C. Faw, Jr. l Asslgneei Associates, Attorney, Agent, 0r Firm-Kane, Dalsimer, Kane,

Bellevllle, Sullivan and Kurucz [22] Filed: Aug. 29, 1974 l 121 App]. NO.Z 501,472 1 [571 ABSTRACT Related Us. Application Data An adjustable modular partition ineluding at least 62 I I three layers of interconnected fire reslstant and sound 1 2 22 [973' deadening material with adjusting means located thereon to adjust the vertical height of the partition [52 us. c1. 52/623 glg "l g i f l l j l i [51] Int. (:1. E04C 2 32 erenfces a room .g 3P 8 3 1581 of cal variations in dimension. The structure for inter- [56] References Cited connecting ad acent modules and the respectiye ad- JUStll'lg structure also has sound deadenmgand fire re- UNITED STATES PATENTS sistant qualities to maintain the integrity of the parti- 1,719,200 7/1929 Schumacher 52/627 X tion system. Minimal connecting apparatus is required 210211375 llH935 Peelle 52/627 X to install the partitions in fixed position within a room. 2,618,028 11/1952 Baker 52/241 X 3,512,819 5/1970 Morgan et a], 52/586 X 2 Claims, 7 Drawing Figures Patent Dec. 2, 1975 Sheet 1 of 5 3,922,830

a h w w w w US. Patent Dec. 2, 1975 Sheet 2 of5 3,922,830

Sheet 3 of 5 Patent Dec. 2, 1975 U.S. Patent Dec. 2, 1975 Sheet4 of5 3,922,830

US. Patent Dec. 2, 1975 Sheet 5 of5 3,922,830

ADJUSTABLE MODULAR PARTITION This is a division of Application Ser. No. 327,609 filed Jan. 26, 1973, now US. Pat. No. 3,866,370.

BACKGROUND OF THE INVENTION There are many modular interior partition systems commercially available today. They are produced in a fixed vertical dimension which is normally eight feet. This produces a problem in many building environments in use today. In particular, the use of prestressed concrete for floors and ceilings imposes a specific problem. A variation as large as three-quarters of an inch over twenty-two feet of horizontal distance in the vertical direction between floor and ceiling can occur. Furthermore, surface irregularities can add an additional one-quarter inch to its variation. Consequently, in this environment, conventional modular partition systems have to be cut to order on site to make such adjustment possible. This is a serious disadvantage.

Another problem existent with presently available modular partition systems is the necessity of a large amount of hardware for installation purposes. It certainly would be advantageous to provide a system which uses minimal hardware for installation and yet retains the integrity of the resultant partition assembly. Naturally ease of installation reduces costs on a time, labor and material basis for construction of a partition assembly. Presently available partition systems with extensive insulation equipment including hardware are costly to assemble and to disassemble when it is desirable to remove or shift the partition to a new location.

Known systems are designed to provide fire resistive and sound deadening qualities which are an asset in the construction field for obvious reasons. Naturally any new design for a partition system which increases the fire resistive and sound deadening qualities without materially affecting the costs would naturally be a valuable improvement.

SUMMARY OF THE INVENTION The present modular partition system is directed toward a structure in which the vertical dimension is adjustable and variable thus making installation possible without the necessity of cutting or other on site adjustments. Furthermore, minimal amount of attaching hardware is required in order to connect each partition module to the floor and ceiling within a room and to connect module to adjacent module and an in module to a wall. In fact, no metal attachments are required at floors, ceilings or vertical joints with respect to the individual panel modules-The absence of vertical joints increases the sound transmission class and fire endurance rating of the panel system. Ease of assembly and disassembly and the adjustable features of the partition system makes it a versatile and low cost modular partition system which can be used in interior wall systems in a manner greatly advantageous over known available structures.

Furthermore, the present partition system includes a combination of layers which contain different physical properties which cooperate with one another to provide a partition module for connection with other partition modules which have increased fire resistant and sound deadening properties. In summary, an adjustable modular partition is provided which may be interconnected with other partitions to form a modular wall system. Each partition includes an inner layer ofa first fire resistant and sound deadening material having opposing sides. A second layer of a second fire resistant and sound deadening material is on each side of the first material so that the first material is located therebetween. A third layer of a third fire resistant and sound deadening material is on the sides of the second material distal from the first material so that the first and second material are located therebetween. Means are provided for fastening the three layers together to form a partition module with'high sound deadening and fire resistant qualities.

In certain embodiments, a fourth layer is provided of a fourth fire resistant and sound deadening material and is located on the sides of the third material distal from the second material so that the first, second and thirdmaterials are located therebetween. Additionally, in certain embodiments, adjustable means are on the partition module positioned so that when the partition module is substantially vertically located between a floor and ceiling, the adjustable means can be shifted to provide engagement between the top and bottom of the partition module and the ceiling and floor respectively.

The method of constructing an adjustable module partition as outlined above is contemplated as well as the method for interconnecting a plurality of such modules to form a wall partition system having the advantageous features outlined above.

With the above objectives, in mind, reference is had to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings:

FIG. 1 is a fragmentary perspective view of a room having a plurality of partition modules mounted therein to form a partition wall system therein; I

FIG. 2 is an exploded perspective view of a pair of partition modules in side-by-side relationship;

FIG. 3 is an enlarged sectional end elevation view of a partition module of the invention;

FIG. 4 is an enlarged sectional end elevation view of an alternative embodiment of a partition module of the invention;

FIG. 5 is a fragmentary enlarged sectional view of the adjustable cap portion of the partition module of the invention;

FIG. 6 is a fragmentary top view of a wall partition system as shown in FIG. 1 including a plurality of partition modules in connection; and

FIG. 7 is an enlarged top sectional view of an alternative embodiment of the partition module of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS As shown in FIG. 2, each partition module 20 is formed by a number of interconnected fire resistant and sound deadening materials. Each module 20 has an inner first layer or core 21 which may be formed of a slab of gypsum board or, alternatively, as shown, a pair of spaced slabs with an air void formed therebetween for insulation purposes and having a pair of sheets laminated to their opposite sides. Bonded to each side of slabs 21 and forming a second layer are a pair of opposed glass fiber panels 22. Alternatively, polystyrene, polyurethane, or polyvinylchloride material can be utilized in place of the glass fiber material with satisfactory results.

A J-shaped ridged member 23 has its inner recess mounted on a vertical edge of panel 22. There are four J-shaped members 23 with one being mounted on each vertical side edge of each panel 22. As shown, inner layer or panel 21 is narrower in width than second layer panels 22 so that when the J-shaped brackets are mounted on the panel 22 edges a recess 24 is formed between each pair of adjacent .l-shaped members. Actually the recess is formed by a combination of the side walls of the pair of adjacent J-shaped members 23 and an edge of gypsum board slab 21. The purpose of the two opposing recesses 24 is for interconnecting a pair of adjacent modules as will be discussed in detail below. The J-shaped channels may be constructed of any convenient rigid material such as steel.

Bonded to each of the two opposed combined surfaces of a panel 22 and a pair of J-shaped members 23 is a third layer or surface 25. Surface 25 is formed of a gypsum board material or any similar common material having fire resistive and sound deadening properties.

The combined result of alternating layers of different fire resistive and sound deadening materials increases the fire resistive and sound deadening properties of partition module 20. As can be seen from FIG. 2, a gypsum board panel 25 is fastened to each of the opposed sides of the inner combination of panel layers. The actual fastening operation can be accomplished in any conventional manner such as by screws or bolts or by a common bonding means such as a rubbery adhesivelike neoprene, or a combination of both.

An adjustable top cap assembly is mounted on the top surface of module 20 in a conventional manner. The adjustable cap assembly includes a U-shaped rigid channel member 26 which is constructed of a conventional metal such as steel. Opposed notches 27 are in the top surface of channel 26 so that when the channel is positioned on the top of module 20, notches 27 will be aligned with slots 24 for mounting of the module as will be discussed below. A pair of gypsum board slabs 28 are mounted respectively on the opposing outer side walls of channel 26 and similarly a pair of sound deadening gypsum board slabs 29 are mounted on the inner surfaces of the side walls of channel 26.

Captured between the inner surface walls of channel 26 and the top surface of panel 21 of module 20 is a resilient spring member 30 which normally tends to bias the top cap assembly including channel 26 away from module 20. Provision of panels 28 and 29 assist in maintaining the integrity of module 20 when the top cap assembly is combined with the module 20 to form a partition module mounted between the floor and ceiling of a room.

Gypsum board panels 28 and 29 are interconnected with channel 26 in a conventional manner such as by a common adhesive means of the type discussed in regard to remainder of module 20. The top cap assembly 31 is captured on the top of module 20 by means of engaging surfaces of panels 25, 21 and 22 along with surfaces of J-shaped members 23. The top cap is captured in the vertical direction by surfaces of the remainder of module 20 and the ceiling surface.

Provision of the air void between the two slabs of panel 21 adds to the variety of different layers utilized to provide the increased sound deadening and fire resistive qualities of the module. It should be kept in mind that each slab 21 in addition to being a single piece of one grade gypsum board may also be a laminate of three pieces of different grades of gypsum board with a highly fire resistant gypsum material sandwiched between a highly rated sound deadening gypsum board. FIG. 3 shows the module 20 installed between a ceiling 32 and a floor 33 of a room. It will be noted for insulation purposes to maintain the integrity of the module 20, if desired, a quantity of compressible mineral wool 34 can be positioned between the compressible top cap assembly 31 and the ceiling surface 32. Similarly, the space between sound deadening boards 29 on the inner side walls of channel 26 and the adjacent side of inner layer or panels 21 can be filled by more compressible mineral wool 35 or, alternatively, by fiberglass of a similar grade as the high density fiberglass utilized for panels 22. Once again the purpose of the filler material 35 is to maintain the integrity of the module 20 and insure that the same high quality fire resistive and sound deadening properties exist fromtop to bottom along the vertical dimension of the module.

Spring 30 may be leaf spring as shown in FIGS. 2 and 5 or, alternatively, it may be any other type of compression spring such as a coiled or helical spring.

Turning to consideration of interconnection of modules 20 in aligned position to form a wall partition 36 across a room 37, reference is initially made to FIGS. 2 and 6. A spline 38 forms the connecting member for each two adjacent modules 20 and for connecting an end module to a wall. Spline 38 is designed to maintain the same high quality fire resistive and sound deadening properties of-the module and therefore is constructed of a gypsum board material or a combination of materials. An example of a combination would be two vertical slabs of gypsum board with a layer of different material therebetween such as glass fiber, polystyrene, polyurethane or polyvinylchloride.

The thickness of spline 38 is narrow enough to permit the spline to fit into aligned recesses 24 and 27 in the module. The spline 38 extends from floor to ceiling and a portion of each side of the spline fits into an adjacent module in the aligned appropriate recesses. When a module is to be connected to the wall of a room, one side of spline 38 is mounted in recesses 24 and 27 of that module and the other side of spline 38 is fastened to the wall in a conventional manner such as by screws, bolts or adhesive. Spline 38 may be mounted in the recesses of the appropriate modules in a number of ways. For example, it can be attached by frictional resistance only, thus providing a readily movable partition due to the ease of disassembly and reassembly. Alternatively, it also can be adhesively bonded in place by use of a readily available commonly used adhesive. The legs of the U-shaped bracket 39 surrounds the spline and the central base of each bracket has a hole 40 for acceptance of a fastener member such as a screw or bolt to mount an adjustable L-shaped tab 41 to the spline. The spline is connected to the ceiling by means of L-shaped tab 41 which is attached to the spline 38 and to the ceiling in a conventional manner such as by bonding or bolts or screws. If desired, a similar bracket 41 can be used to mount the spline to the floor. The only connection between module 20 and either or both of the floor and ceiling other than face-to-face frictional engagement is by means of L-shaped tabs 41 and 42. Consequently, it can be seen how only minimal hardware is required for mounting of the modules in a room to form a wall partition system.

As shown in FIGS. 2 and 4, if the dimensional height of the room between floor and ceiling is excessively great, one or more shims 43 may be positioned between the bottom of the module 20 and the floor. The use of shims 43 is optional depending upon a situation where the dimensional difference between floor and ceiling is excessive. Similarly, filler side panels of gypsum board 44 may be positioned around the base of module 20 to fill in any recesses in that portion of the module. These recesses may occur because of vertical dimensional differences between panels 21, 22 and 25.and the presence or absence of filler gypsum board slabs 43. As shown in FIGS. 2 and 4, three shims 43 are added to maintain the tight sealing engagement between ceiling and floor. The spring 30 forcing upward against the underside of top cap assembly 31 and downward against the top surface of the remainder of module 20 thereby exerting a force against the floor and ceiling to retain the tight engagement between 'the module 20 and the floor and ceiling.

FIG. 7 shows several alternative structural arrangements for module 20 and is appropriately identified as module 20a. A fourth layer or surface shell 45 is in surrounding relationship with the outer surface of panels 25. A preferred material for the shell is an asbestos reinforced plastic material. Alternatively, the shell may be of a vinyl material or a thick paint surface. Shell 45 acts as an additional fire resistance and sound deadening material surface and cooperates with the other alternate mixed classes of materials to form a module of various layers having the desired qualities. It should be kept in mind that shell 45 may also be applied in a similar manner to module 20 as in 20a. Module 20a also shows an additional means for fastening the J-brackets 23a to the remainder of the module structure. A number of self-tapping screws 46 of a predetermined quantity can be utilized to interconnect adjacent J-brackets 23a and opposing panels 22 along with central layer or panel assembly 21. Similarly, a predetermined number of self-tapping screws 47 can be utilized to connect the adjacent second and third layer panels to the .I-brackets at any desired number of location points on the surface of module 20a. Naturally, screws 46 and 47 can also be utilized in connection with the embodiment of module 20. All components of module 20a which correspond to similar components of module 20 are represented by the same numerals with a subscript a added thereto.

In assembling the individual modules 20 to form a wall-to-wall partition assembly 36 as shown in FIG. 1, an end spline 38 is mounted on one wall surface and then a module 20 is connected to the end spline 38. Spline 38 is connected to wall and ceiling and floor as desired by means of appropriate tabs as discussed above. Adjustment between vertical heights at any point along the width of the room is readily accomplished by means of spring loaded adjustable cap which is forced by the spring into engagement with the ceiling while the module 20 is forced into engagement with the floor. As discussed above for unusual dimensional heights, appropriate shims can be employed between the floor and the base of module 20. It should also be kept in mind that the top cap can readily be mounted on the base of the module as well as the top as shown to operate in a similar manner. In that arrangement naturally the shims would be positioned at the top of the module if they are needed to engage with the ceiling.

A shim 38 is then mounted in the exposed edge of the first module 20 in an appropriate manner as described above and is mounted to ceiling and floor as desired. A second module is then mounted on the exposed surface of the shim in a similar manner thereby interconnecting the two partition modules 20 to maintain the integrity of the combined partition wall of two panels. The adjustable top cap of the second module 20 will then be shifted by the spring to engage with the ceiling and to accommodate any dimensional variations in the ceiling and floor from the dimensions at the location of the first module. Once again, if shims are required they can be positioned between the second module 20 and the floor. In this manner, the remainder of the modules 20 can be interconnected with those installed until a final end 'spline 38 is employed to fasten the partition wall 36 to the opposite wall of the room. The adjustable top caps along with the provision of shims where necessary accommodates all dimensional variations across the room and eliminates the necessity of cutting and fitting of panels as well as eliminating the necessity of excessive installation hardware. In this manner, the installation costs for a partition assembly are greatly reduced in regard to both time and material utilized.

Although the particular embodiments discussed above and shown in the drawings relate to interior partition systems, the present design is readily adaptable to use as an exterior wall surface. For example, a coating may be provided on the exterior surface of the module 20 such as by lamination to form a finished product acceptable for exterior use. A material which has been found to operate satisfactorily for this use is a material identified as Korad A film which is a durable all-acrylic polymer. The material is manufactured by the Rohm and Haas Company of Philadelphia, Pa.

In regard to particular materials employed for various components of module 20, it is contemplated that panels 22 can be constructed of polystyrene foam, polyurethane foam or a polyvinylchloride foam as well as high density glass fiber as discussed above. Common types of adhesive can be utilized for the bonding of components of the module as noted above and additionally an intumescent paint can be added to the adhesive to improve the bonding surface.

Plastic coating 45 as mentioned above is based on a slurry of asbestos fiber and synthetic latex. The latex employed in the slurry can be one of a great variety of commonly used and commercially available latices of, polyvinylchloride, acrylics, polyacrylics, phenolics, polyurethanes, styrene-acrylonitrile or acrylonitrilebutadiene-styrene or other thermoplastics or thermosetting resins. Finally, in adapting the module 20 for exterior use, in addition to Korad A coating as mentioned above, plastic coatings are contemplated to achieve the same results. For example, coatings substantially based on polyvinylchloride or polyurethane are conceivable.

Thus, the above discussed objectives, among others, are effectively attained.

We claim:

1. An adjustable partition module comprising:

an inner layer of a first fire resistant and sound deadening material having opposing sides;

a second layer of a second fire resistant and sound deadening material on each side of said first material so that said first material is located therebetween;

a third layer of a third fire resistant and sound deadening material on the sides of said second material distal from said first material so that said first and second material are located therebetween;

a fourth layer of a fourth fire resistant and sound deadening material on the sides of said third material distal from said second material so that said first, second and third material are located therebetween;

means for fastening said four layers together to form a partition module with high sound deadening and fire resistive qualities;

each of the opposed vertical sides of the partition module containing a vertical recess adapted to receive a portion of a vertical spline member therein; and

at least the surfaces forming the vertical recess being covered by a rigid supporting channel for stiffening predetermined portions of the module and which is adapted to be resiliently deformed sufficiently for accommodation of dimensional differences in spline members and to frictionally engage with an appropriate spline member so as to facilitate interengagement therewith.

2. An adjustable partition module comprising:

an inner layer of a first fire resistant and sound dead- 8 ening material having opposing sides;

a second layer of a second fire resistant and sound deadening material on each side of said first material so that said first material is located therebetween;

a third layer of a third fire resistant and sound deadening material on the sides of said second material distal from said first material so that said first and second material are located therebetween;

means for fastening said three layers together to form a partition module with high sound deadening and fire resistive qualities;

each of the opposed vertical sides of the partition module containing a vertical recess adapted to receive a portion ofa vertical spline member therein; and

at least the surfaces forming the vertical recess being covered by a rigid supporting channel for stiffening predetermined portions of the module and which is adapted to be resiliently deformed sufficiently for accommodation of dimensional differences in spline members and to frictionally engage with an appropriate spline member so as to facilitate interengagement therewith. 

1. An adjustable partition module comprising: an inner layer of a first fire resistant and sound deadening material having opposing sides; a second layer of a second fire resistant and sound deadening material on each side of said first material so that said first material is located therebetween; a third layer of a third fire resistant and sound deadening material on the sides of said second material distal from said first material so that said first and second material are located therebetween; a fourth layer of a fourth fire resistant and sound deadening material on the sides of said third material distal from said second material so that said first, second and third material are located therebetween; means for fastening said four layers together to form a partition module with high sound deadening and fire resistive qualities; each of the opposed vertical sides of the partition module containing a vertical recess adapted to receive a portion of a vertical spline member therein; and at least the surfaces forming the vertical recess being covered by a rigid supporting channel for stiffening predetermined portions of the module and which is adapted to be resiliently deformed sufficiently for accommodation of dimensional differences in spline members and to frictionally engage with an appropriate spline member so as to facilitate interengagement therewith.
 2. An adjustable partition module comprising: an inner layer of a first fire resistant and sound deadening material having opposing sides; a second layer of a second fire resistant and sound deadening material on each side of said first material so that said first material is located therebetween; a third layer of a third fire resistant and sound deadening material on the sides of said second material distal from said first material so that said first and second material are located therebetween; means for fastening said three layers together to form a partition module with high sound deadening and fire resistive qualities; each of the opposed vertical sides of the partition module containing a vertical recess adapted to receive a portion of a vertical spline member therein; and at least the surfaces forming the vertical recess being covered by a rigid supporting channel for stiffening predetermined portions of the module and which is adapted to be resiliently deformed sufficiently for accommodation of dimensional differences in spline members and to frictionally engage with an appropriate spline member so as to facilitate interengagement therewith. 